Re-grouting Valsoera dam grout curtain

F. Besseghini1, Ph. Lazaro1 and N. Brizzo2

1
Hydraulic Structure Department, Lombardi Engineering Limited, Via R. Simen 19, 6648 Minusio, Switzerland
2
IREN S.p.A.,corso Svizzera, 95, 10143, Torino - Italy
E-mail: fulvio.besseghini@lombardi.ch

plug 10 m high closing the valley gorge (Figures 1 and 2).

Summary

Water leakage through the dam body and increase of uplift

pressures are evidences of structure aging that might reduce
the efficiency of dam stability safety factors. A proper
monitoring system helps to measure and localize leakage and
uplift pressure distribution and allows the implementation of
the best methodology to mitigate such issues. An efficient
reassessment of the upstream face water tightness and/or
grout curtain might become complicated due to additional
constraining aspects such as dam location and accessibility,
unknown degradation of the construction materials, operation
of the plant, dead storage volume, upstream silt deposit, etc.
In this paper the rehabilitation of the arch-gravity dam of
Valsoera is presented. After identification of a rising leakage
and a change of uplift pressure values, as evidenced by the Figure 1: The Valsoera Dam
observation of the historical measurements, and after
checking the dam stability, the upstream face was repaired
and the central part of the grout curtain was re-grouted using
the G.I.N. method. The 54 m high dam, with an upstream face
covered with locally shaped masonry blocks is located at an
elevation of 2400 m asl. It was constructed in the early fifties
and since then the scheme has been operating without any
reservoir draw-down. The new grouting process of the grout
curtain was designed after conduction of in-situ trial tests
which allowed the definition of the best grout mix as well as
the appropriate grouting procedure.
The effectiveness of the remedial works has been confirmed
both during the works implementation and most importantly
after few years of operation.

The Valsoera Dam

The Valsoera Dam is part of the integral hydroelectric system

of the Orcos valley owned by Iren Energy S.p.A. The
reservoir of Valsoera was built by AEM Turin during the
construction of the hydroelectric power plant Valsoera-
Telessio and was commissioned in 1955. It was designed to
create a seasonal reservoir with a live storage of 7.2 Mm3.
The arch gravity dam is 54 m high and is located at an
elevation between 2360 m asl (dam foundation) and 2414 m
asl (dam crest). The total crest length is 220 m. The lower
central part of the dam is composed of a cyclopean concrete Figure 2: Valsoera Dam Central body dam cross-section
Rising leakage and change in the uplift pressure
The dam manifested a rising water leakage and increase in
uplift pressure measured in the central part (plug). Studies
carried out in 2005 reported that the increase of leakage
recorded in the latest analyzed years (2004-2005, 5 and 7 l/s,
respectively) were to be attributed to the joints on the left
bank of the dam section above an elevation of 2'400 m asl
(joints from G0b to G5). The higher uplift pressure values
were recorded in the central plug zone.
Between 2007 and 2008, a preliminary intervention and
further studies were carried out based on specific
investigations (boreholes, grouting tests, and Lugeon tests).
The boreholes showed the presence of highly fractured gneiss
in this part below the plug on the right bank. The grouting
tests were carried out at low pressures, while relatively high
grouted volumes were reached. Consequently, the treatment
of the rock foundation was judged to require further
optimizations.
Leakages
Measurements of water seepage through the upstream face of
the dam are performed automatically on a daily basis through
two weirs, located at the lowest portion of the inspection
gallery. They measure separately the water leakage on the
right and left bank. A third weir device, located in the
inspection gallery at the dam toe, collects water from both
sides, and the drainage area of the central concrete plug.
Figure 3 shows the leakage evolution between the years 1979
and 2008.
Figure 3: Leakage recorded at Valsoera dam.
In the first period, until the year 1982, the water leakage
reached 5.8 l/s. In the period 1983-1986 there was a
significant reduction of the maximum leakage (up to 2 l/s).
This was due to the effects of the maintenance executed in the
left and right bank during the summer seasons of 1983 and
1984. During the period 1986-1992 a further increase of
leakage up to 6 l/s was noticed. A new reduction occurred in
the years 1993 to 2001 (up to 3.2 l/s) as a result of a new
intervention similar to the previous one that has affected the
upper part of the dam in the summer of 1993. Since 2001, a
further increase of the total water leakage with a maximum
value of 7 l/s in 2005-2006 was measured. Following the
intervention of joint grouting (summer 2007) the total
leakage, in 2008, amounted to approx. 5 l/s. Since 1998 an
increasing leakage trend can be observed (Figure 3). The
maximum leakage corresponds to the highest water level in
the reservoir.
Uplift pressure distribution
The uplift pressures at the Valsoera dam are measured by ten
automatic piezometers, located along the entire perimeter of
the inspection/drainage gallery as illustrated in Figure 4.
Figure 4: Monitoring system Piezometers distribution.
The piezometric measurements since the beginning of 1979
generally showed a slightly decreasing trend for the uplift
pressure records. In the years 1985-87, the piezometers PZ06
and PZ01 showed a significant reduction of the uplift
pressure. The measurements conducted after the year 2000
using the piezometers PZ02, PZ06, PZ08, PZ09, PZ12, PZ13
and PZ0A recorded the minimum uplift pressure values of the
period from 1979 to the present day. Figure 5 illustrates the
piezometric levels recorded from 2005 to 2008, compared
with the reservoir levels.
2420
2415
2410
PIEZOMETRIC MEASUREMENTS
RESERVOIR LEVEL (m asl)
2405
2400
2395
2390
2385
2380
2375
2370
2365
2005 2006 2007 2008
PZ 01/02/0A PZ 05/12/12/17 PZ 06/08/09 Reservoir
Figure 5: Monitoring system Piezometric measurements.
It must be mentioned that no correlation could be observed
between the storage elevation and the piezometers PZ05,
PZ12, PZ13 and PZ17. The piezometers PZ01, PZ02 and
PZ0A show a certain correlation of the pressure values if
compared to the water level variation in the reservoir. In
order to reduce the uplift pressures that currently affect the
dam in some sections, an integration of the grout curtain and
an extension of the drainage scheme were considered.
Dam stability analysis
The dam stability analysis at Valsoera Dam was carried out
considering the maximum operating level in the reservoir
(2413 m asl). The safety factor (SF) was estimated for
different uplift pressures.
For the calculation the following values were considered:
cohesion: c = 0 kPa; friction angle 48.5; safety factor SF =
1.5.
Figure 6: Variables considered for the stability analysis
against sliding.
The uplift pressure coefficient X [%] is calculated using the
uplift pressure in the drainage holes compared to the
upstream reservoir conditions (X=35%). In the present
conditions of Valsoera Dam, considering the uplift pressure
values recorded by the piezometers, the SF against sliding is
2.2.
Repair of the upstream face
The maintenance works to be performed consisted in cleaning
and re-grouting the joints between the masonry blocks
embedded in the upstream dam face. Similar interventions
were carried out in 1981, 1983-1984, 1993 and 2007, as
illustrated in Figure 7.
Figure 2: Valsoera Dam Upstream face repair works.
In 2010 a new maintenance program was planned in the lower
part of the dam, below the elevation 2395 m asl up to the
foundation level, in the central section between joints G5 and
G6. The total area affected corresponds to approx 1400 m2.
The general methodology consisted of removing and re-
grouting of the joints between the masonry blocks,
proceeding from bottom to the top sections. For the treatment
of the vertical joints between the dam blocks, a two-
component mortar with high adhesion and flexibility was
used. The grouting and the filling of the joints between the
masonry blocks have been made with a mix of cement-based
thixotropic and fiber-reinforced. For the grouting behind the
masonry blocks a ready-mix mortar was used.
Re-engineering of the grout curtain
Preliminary investigations and grouting tests
In order to study the characteristics of the different materials
in the foundation of the dam, a series of investigations were
carried out in 2007. They were related to the concrete of the
body dam, the concrete plug, and finally the rock foundation
below the plug. These investigations consisted of six
boreholes, drilled in the area of the plug from the inspection
gallery on the right bank. Eight permeability tests as well as a
grout mix testing program were also carried out. The drilling
scheme is shown in Figure 8.
Figure 8: Central plug investigations.
The grouting tests considered the following limits: flow rate
between 5 and 20 l/min; pressures up to 30 bar (20 bar in the
dam body); maximum volumes take of approx 70 l/m, and
G.I.N. (pressure x volume) values between 800 and 1000
bar.l/m.
The unexpected low rock quality found in some portions of
the foundation resulted in higher grouting volumes than
anticipated. It must be mentioned that the above values were
adjusted to meet the effective site conditions. Three different
materials with different mechanical properties were
identified: the concrete plug with fair to good conditions; the
rock composed of massive gneiss with few fractures in the
central part of the valley detected by the boreholes 8, 9, and
in the right bank in the boreholes 12 (upper) and 13; the rock
composed of gneiss strongly fractured found below the
central dam plug in the right bank (borehole 10, 11 and lower
length of 8 m of the borehole 12). The Lugeon permeability
tests registered values up to 6 UL. The grouting tests have
generally been interrupted in all boreholes and resumed the
day after because in the first grouting phase the grout take
reached relatively significant values (200-300 l/m).

Re-grouting methodology
One of the key aspects of the maintenance works for the
Valsoera Dam was the re-grouting of the grout curtain using
the Grout Intensity Number technique (G.I.N.) [1]. The entire
section of the rock foundation below the elevation of 2'392 m
asl was consequently treated as illustrated in Figure 9. The
total area of rock foundation affected by the new grouting
works appeared to be greater than 2000 m2. The grouting
operation was carried out starting from the
inspection/drainage gallery. Difficulties were encountered due
to restricted operation space.
Figure 9: Extension and distribution of grouting works.
The G.I.N method limits the grouting pressure P, the volume
of grout V and the grouting intensity number G.I.N. (i.e. the
product P x V).
The main features of the G.I.N. method are: use of a single
stable grout mix during the entire grouting process; a steady
low-to-medium rate grout pumping to avoid pressure peaks;
monitoring in real time of the parameters of pressure, flow,
grouted volume, and penetrability as a function of time, all by
means of graphs drawn directly on the site. The control of the
grouting process was carried out using of automatic
equipment which allows the programming and continuous
recording of the aforementioned parameters. The grouting
process is stopped when the function P = P (V), grouting
pressure as a function of the total grouted volume (grouted
per linear meter), recorded in real time on the PV diagram,
intersects the chosen G.I.N. curve (Figure 10).
Figure 10: G.I.N. curve for Valsoera maintenance works.
The grouting process was stopped when one of the following
three conditions occurred: achieving the target G.I.N. = PxV
(grout control curve); reaching the volume limit V = Vmax;
reaching of pressure limit P = Pmax. For the maintenance
works of the Valsoera Dam, the G.I.N. number was set to
1000 l/m x bar, limiting the maximum pressure to 25 bar
(static pressure, measured with the pump off). The maximum
volume was limited to 500 l/m. The grout hole pattern was
arranged into two rows (Figure 11). The first row is formed
by drilled holes, carried out from the inspection gallery and
inclined upstream at 10, with a variable length from 30 m in
the area of concrete plug to 15 m along the abutment. Those
perforations are distinguished, depending on the succession of
executions, in primary, secondary, and eventually tertiary
holes. The second row includes the control drillings. They run
parallel to the centerline of the dam, 50 cm downstream of the
first row, inclined upstream at 10 with inclinations variable
in left and right directions. Their length varied between 20 to
40 m.
Figure 11: Grout hole pattern.
The grouting stable mix used corresponds to the following
characteristics: viscosity (standards Marsh cone diameter 4.5
mm): 38 45 seconds; cohesion: <1.5 mm (25 Pa); setting
time: <5% after 2 hours; Fine Portland cement type: CEM I
52.5; cement specific surface (Blaine): > 4300 cm2/gr; W/C
ratio (weight ratio between water and cement): 0.7. The
grouting perforations were performed by rotary destructive
 30
percussive drilling machine with circulation of fluids. The
G.I.N. CURVE
control drillings were achieved by means of continuous PRIMARY HOLES
double core drillings equipment. The Lugeon permeability 25 SECONDARY HOLES
tests were performed measuring absorptions for at least 3 TERTIARY HOLES
values of pressure, increasing and decreasing trends (2-5-8-5-
20

PRESSURE P (bar)
2 bars).

15
Final controls

In Figure 12 and 13 an overview of the volumes of grout 10

absorbed into the hole is presented, both in terms of total

volume and in terms of the average volume per m of the hole. 5
The absorbed grout volumes are quite well distributed with an
absorbtion between 55 and 90 l/m.
0
0 50 100 150 200 250 300 350 400 450 500 550
3000 VOLUME V (l/m)
TOTAL ABSORBED GROUT VOLUME (l)

2500 Figure 14: Final grouting values.

2000
The final results for the primary and secondary holes are
1500
generally overlapping in the central part of the graph showing
an apparently equivalent response of the rock mass.
1000 Theoretically, the final G.I.N. value within the primary holes
500
should have been observed in the lower part of the graph (low
pressure and higher volume), while those recorded in the
0 secondary holes should have been observed in the upper part
S9
P9
S7
P7
S5
P5
S3
P3
P1
S2
P2
S4
P4
S6
P6
S8
P8
P17
S15
P15
S13
P13
S11
P11

S10
P10
S12
P12
S14
P14
S16
P16

HOLE
of the graph (lower volumes and higher pressures). The
Figure 12: Total grouting volume absorbtion. overlapping of the values is explained by the fact that the
primary and secondary holes are positioned with a certain
spacing and thus may not interact. Additionally, this is
100 explained by the fact that the grouted rock mass was already
AVERAGE ABSORBED VOLUME (l/m)

90
treated during the construction of the dam and therefore the
80
main fissures of the rock (those which generally record
70
important absorption in primary holes) were already filled.
60
The tertiary holes performed close to the central dam concrete
50
plug showed absorptions between 250 and 330 l, and an
40
average cement take of 10-13 l/m, always reaching the upper
30
limit of the G.I.N. curve in terms of maximum pressures. The
20
tertiary holes, given the encouraging results obtained in the
10
area of the plug, have not been extended to the dam abutment.
0
The perforation control was limited to the central concrete
S9
P9
S7
P7
S5
P5
S3
P3
P1
S2
P2
S4
P4
S6
P6
S8
P8
P17
S15
P15
S13
P13
S11
P11

S10
P10
S12
P12
S14
P14
S16
P16

HOLE
Figure 13: Grouting absorption Average volume for meter
of hole.
Figure 14 shows the final values achieved in the grouting
works for primary, secondary and tertiary holes.
plug area. The grouting revealed a grout take comparable to
the grouting performed in the tertiary holes. The volumes of
absorbed material are generally well distributed showing a
substantial uniform response of the rock mass. Passing from
primary to secondary and tertiary holes, the absorbed volumes
decrease, and the final grouting pressure increase, in
accordance with the G.I.N. method. In order to check the
effectiveness of the grouting, some permeability tests were
performed within the control borehole. The diagram of Figure
15 summarizes the main grout take values at different depths.
The permeability recorded is always less than 1 UL.
 PERMEABILITY U.L.
0.00 0.20 0.40 0.60 0.80
0.00

5.00

10.00
DEPTH (m)

15.00

20.00

C1
25.00
C2
C5
30.00
C6

35.00 C7
C10
40.00

Figure 15: Summary of Lugeon tests.

Conclusion

This paper illustrates a very particular work consisting of re-

grouting procedure of an existing grout curtain. The scope of
this work was to limit water infiltrated and to reestablish the
original conditions of the dam foundation as far as possible.
The application of the G.I.N. method allowed the use of
higher grouting pressures with minimum risk of damage to the
existing structure combined with stable fine cement grout.
This procedure appeared to be a determinant factor in
ensuring the success of the grouting program.

Acknowledgements

The authors acknowledge the authorities of Iren Energy

S.p.A. for their positive collaboration and help providing
optimal work conditions.

References
[1] Lombardi G., Deere U. (1993). Grouting design and control using the
G.I.N. principle. Water Power & Dam Construction, June 1993, pp.
15-22.
[2] Turcotte G., Savard B., Lombardi G., Jobin H. (1994). The use of
stable grout and G.I.N. technique in grouting for dam rehabilitation.
Annual Meeting Canadian Dam Safety Conference CDSA and
CANCOLD, Winnipeg, Manitoba, Canada; October 1994, pp. 137-
161.
[3] Iride Energia, Lombardi Eng. Ltd, (2009). Progetto esecutivo dei
lavori di manutenzione straordinaria Technical Report 7004.4-R-1
(unpublished report).
[4] Lombardi G. (1996) Selecting the grouting intensity. The International
Jounal on Hydropower & Dams; Volume Three, Issue Four, pp. 62-66.